Wearable protective system and method for making the same

ABSTRACT

An apparatus is disclosed, having an attachment mechanism for attaching a base material to a body part of a wearer. The apparatus further includes a padding layer overlaying the base material, and a plurality of scales. Each scale of the plurality of scales is independently attached to the padding layer, each scale either at least partially overlapping or at least partially underlying one or more adjacent scales to enable flexible adherence to a shape of the body part of the wearer.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. patent application Ser. No.62/127,270, filed on Mar. 2, 2015, and entitled “WEARABLE PROTECTIVESYSTEM AND METHOD FOR MAKING THE SAME,” which is incorporated byreference herein in its entirety.

BACKGROUND

The present invention relates to protective system, and moreparticularly to a wearable protective system for protecting a portion ofa wearer's anatomy from forces such as blunt impact, abrasions,slashings, cuttings, punctures, or the like.

Various protective gear, such as knee pads, elbow pads, etc., areprevalent in modern activities, particularly in activities such asskateboarding, skating, or the like. Most of these protective gearinclude only a unitary pad, or a padding layer overlaid by a rigidencasement. The former, which lack an outer hard shell encasement, donot provide adequate protection or impact absorption. The latter, whileoffering somewhat adequate protection, are bulky, inflexible and do notprovide full mobility by the wearer. Conventional protective gear eitherdo not adequately absorb a force exerted upon it, nor adequatelydistribute such force away from the point of impact so as to lessen theforce received by a part of a wearer's anatomy being covered by thegear. Because of these inadequate absorption and distribution qualities,most protective gear tend to be bulky in order to meet at least aminimum standard of effectiveness. Protective gear with a lower profileis typically ineffective in offering protection to a wearer.

SUMMARY

This document presents a protective assembly that includes a scalesystem of a number of scales, one or more layers of impact material, awrap for attaching to a part of a wearer's body (such as the wearer'sknee or elbow, or the like).

In one aspect, an apparatus includes an attachment mechanism forattaching a base material to a body part of a wearer. The apparatusfurther includes a padding layer overlaying the base material, and aplurality of scales. Each scale of the plurality of scales isindependently attached to the padding layer, each scale either at leastpartially overlapping or at least partially underlying one or moreadjacent scales to enable flexible adherence to a shape of the body partof the wearer.

The details of one or more embodiments are set forth in the accompanyingdrawings and the description below. Other features and advantages willbe apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects will now be described in detail with referenceto the following drawings.

FIGS. 1A-1H illustrate a scale and a scale system for absorbing anddistributing impact energy.

FIGS. 2A-2C illustrate the scale system in further detail.

FIGS. 3A-3B illustrate impact material.

FIGS. 4A-4B illustrate impact material and scale interaction.

FIGS. 5A-5B illustrate a fastening system in accordance withimplementations described herein.

FIGS. 6A-6E illustrate various other aspects of a fastening system inaccordance with implementations described herein.

FIG. 7 shows a knee pad product in accordance with implementationsdescribed herein.

FIG. 8 illustrates a quick locking mechanism for the impact material.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This document describes a protective assembly. As shown in FIG. 7, aprotective assembly 100 includes a scale system 102 formed of a numberof scales 104, and one or more layers of impact material (not shown).The protective assembly 100 further includes a wrap 106 or otherattachment mechanism for attaching to a part of a wearer's body (such asthe wearer's knee or elbow, or the like).

In accordance with some implementations, the scale system 102 includesone or more scales 104. Each of the scales 104 is a durable andabrasion-resistant plate that is shaped, formed and modeled afterexamples found in nature, showcasing similar shape and overlappingpattern. Accordingly, each of the scales 104 is generically orspecifically formed to fit into an overlapping pattern of scales to formthe scale system 102.

In such an arrangement, a scale of the scale system 102 that receives aforce or other impact energy is able to distribute that force (i.e. byenergy cascade) to underlying and/or adjoining scales, such that nosingle scale receives and absorbs the full or majority portion of theforce. Impact energy refers to energy encountered by any part of theprotective assembly 100 due to some variation of contact with anothersurface. Impact energy cascade refers to the process by which a scale104 that overlaps other scales 104 disburses impact energy to otherscales 104 it overlaps. The scale system 102 includes an assembly ofoverlapping scales 104 attached to the wrap 106, and overlaying one ormore layers of protective impact materials (not shown). In someimplementations, each scale 104 is formed with a flare, i.e., a designelement that warps the scale shape out toward other scales 104 to allowfor adjacent scales to fit amongst, and slide past, other scales 104 inthe scale system 102.

The impact material underlying at least a portion of the scales 104 orscale system 102 can include any material to absorb further impact, suchas foam, plastic, rubber, cloth, fiber, or the like. The impact materialcan be formed of one or more layers of impact-absorbing orimpact-resistant material. The wrap 106 includes any of a number ofcomponents and materials to keep the other components, such as scales104 and impact material, in place. In some implementations, as will bediscussed further below, the protective assembly 100 includes a fastenersystem (not shown). The fastener system includes one or more componentsassociated with or connected to the wrap 106, and used to secure theprotective assembly 100 to a part of the wearer's anatomy, such as thewearer's leg, knee, elbow, head, or other parts of the wearer's body.The fastener system is ergonomically designed to be low-profile and yetretain the protective assembly 100 in place over the desired part of thewearer's anatomy.

FIGS. 1A-1H illustrate various aspects of the scales 104 of the scalesystem 100 of the protective assembly 100. FIGS. 1A-1D show a preferredimplementation of a scale 10. In accordance with preferredimplementations, each scale 10 has a back surface that includes anattachment mechanism to attach to a protective assembly, such as kneepad, elbow pad, or the like. Each scale 10 may be attached or removedfrom the protective assembly by a diamond shaped interface B.1. Thediamond shaped interface provides a surface for optimal packing densityof scales on the impact material, and allows each scale 10 to fit amongother scales 10 in the scale system.

Each scale 10 back surface employs one or more toe surfaces B.2. The toesurface is positioned on the back surface of the scale 10 and is formedas a rearward deflection of the scale material, with design permeatingto and partially defining the shape of the front of the scale 10 due tothe approximately even thickness of the scale at the toe surface A.1,B.2. The toe surface is located on the inferior portion of the scalerelative to the transverse plane of the body, and covers a portion ofthe back surface of the scale where the scale interacts with asubsequent or adjacent scale. Rearward deflection of the scale materialprovides a contact point on the back surface of the scale, whichcontacts the front surface of subsequent or adjacent scales, enablingthe disbursement of impact energy and providing clearance betweenindividual scales for inter-scale sliding

In accordance with some implementations, the scale back surface furtherincludes flares A.2, B.3. The flares are an extension [A.3, B.4] of thetoe surface and provide a similar effect on the shape of the scale. Theflares allow room for adjacent overlapping and underlapping scales.Flares are located on the back surface of the scale with designpermeating to and partially defining the shape of the front surface ofthe Scale due to the approximately even thickness of the scale, as seenat A.2 and B.3. In preferred implementations, flares are located on themedial and lateral parts of the scale 10 relative to the sagittal planeof the body.

Accordingly, the scale fits ergonomically around a part of an anatomy ofa wearer, such as the wearer's knee. The curvature of the scale isdesigned to maximize ergonomic aspect. In some aspects, the curvature ofeach scale cross-section parallel to the sagittal plane of the bodymatches leg cross-section surface profile of same location, as seen inFIG. 1C.1. The curvature of each scale's cross-section parallel to thetransverse plane of the body matches a wearer's leg's cross-sectionsurface profile of the same location, as shown in FIG. 1D.1. The designand shape of the scale preserves the wrap and the impact material fromexposure to destructive elements, and protects underlying layers fromabrasion, wear, fraying, scuffing, etc., as shown in FIG. 1E. Further,the scale protects underlying layers and regions from cutting, slashing,laceration, etc., as shown in FIG. 1F, and protects underlying layersand regions from puncture, piercing, penetration, perforation, etc., asshown in FIG. 1G. Importantly, each scale disburses impact energytransferred to the impact material across a larger surface area than theinitial area that the impact energy was received by the scale.

Impact energy administered to one point on a scale's front surface isdistributed to the impact material and to additional scales by means ofeach scale's perimeter, as shown in FIG. 1H.1. Impact energydistribution to a larger area of the impact material lowers the pressureexperienced by a wearer during impact. The scale system enables a wearerto slide across surfaces when a contact point with a surface is on thescale. Such sliding can be intentional, to execute maneuvers, braceagainst objects, or slow down, for example. Or the sliding can beunintentional, such as can occur when a user falls, or when sliding toavoid injury incurred by tumbling.

Scale System

As discussed above, the scale system enables user to slide acrosssurfaces when a contact point with the surface is across one or morescales, such as during intentional sliding used to execute maneuvers,brace against objects, or slow down, or during unintentional slidingthat often occurs when a user falls, and where sliding helps avoidtumbling. The scale system disburses impact energy on a per scale basis,and on an impact energy cascade basis, such as impact energy transferredto the impact material across a larger area than the initial area thatthe impact energy was administered onto the contact scales.

The scale system also disburses impact energy administered to one pointon scale front surface will be distributed, in a cascading manner, tothe impact material and to additional scales by means of the scale'sperimeter, as shown in FIG. 2A.1, and impact energy administered fromcontact scales to subsequent or adjacent underlying scales will befurther disbursed, in a cascading manner, to additional subsequentscales that the previous scale overlaps, as seen in FIG. 2A.2.

The scale system further provides impact energy distribution to a largerarea in the impact material, by means of disbursement by each individualscale and by means of disbursement across multiple scales, which lowerspressure experienced during impact. The scale system preserves the wrap106 and impact material from exposure to destructive elements. As such,the scale system protects underlying layers from abrasion, wear,fraying, scuffing, etc., as shown in FIG. 2B.1, protects underlyinglayers from cutting, slashing, laceration, etc., as shown in FIG. 2B.2,and protects underlying layers from puncture, piercing, penetration,perforation, etc., as shown in FIG. 2B.3. The scale system itself fitsergonomically around a wearer's knee or other body part, such as awearer's elbow, wrist, hip, etc. Accordingly, the multiple, theindividual, rigid scales enable the scale system to assume curved shapesas seen in FIG. 2C.1, and permit movement of one scale across another,enabling scale system to assume, and transition between, multiple curvedshapes, as seen in FIG. 2C.2.

Impact Material

The impact material can be placed at one or more coverage zones toprotect major frontal components of a wearer's body, such as a knee.

For example, a shape of the impact material can cover the approximateshape of the patellar ligament. The impact material covers over thesurface of the skin up to approximately one inch above the superiorportion of the patella, as shown in FIG. 3A.1, to define a superiorcoverage zone limit, and covers over the surface of the skin down to theapproximate location of the termination of the patellar ligament intothe tibial tuberosity, as shown in FIG. 3A.2, to define an inferiorcoverage zone limit.

The impact material covers over the surface of the skin medially tofully cover the bulge on surface of the knee caused by the medial tibialand femoral condyles and associated tissues, as shown in FIG. 3A.3, todefine a medial coverage zone limit, and covers over the surface of theskin laterally to fully cover the bulge on the surface of the kneecaused by the lateral tibial and femoral condyles and associatedtissues, as shown in FIG. 3A.4, to define a lateral coverage zone limit.

In some implementations, the impact material shape has corners roundedbetween the superior, as shown in FIG. 3A.1, inferior [FIG. 3A.2],medial [FIG. 3A.3], and lateral [FIG. 3A.4] limits, and the coveragezone is shaped as an asymmetrical diamond shape projected onto thesurface of the knee. The impact material employs features to enableassumption of three-dimensional shape from a two-dimensionalmanufactured state, and is left/right specific for optimized ergonomics.

In some implementations, a “lightning split” or jagged separation orpartial offset, enables the impact material to assume conic shape ofsurface of knee local to the patella from a flat manufactured state, asillustrated in FIG. 3B.1. Offset cut sections improves material coverageover the length of the split, as shown in FIG. 3B.2. The superior medialsplit enables impact material to assume curved shape of surface of kneemedial to the patella from flat manufactured state, as shown in FIG.3B.3, and a superior lateral split enables the impact material to assumea curved shape of the surface of a wearer's knee lateral to the patellafrom the flat manufactured state, as seen at FIG. 3B.4.

The impact material employs features to enable flexibility, reducematerial use, and increase ventilation. For instance, in someimplementations, a central portion of impact material employs a patternof swells to enable multi-directional flexibility, reduce material use,and allow ventilation to frontal portion of knee, as shown in FIG. 3B.5and FIG. 4A.1. Medial, lateral, and superior portions of the impactmaterial employ curved grooves to enable flexion of the impact materialperpendicular to the direction of the groove, to reduce material use,and to allow ventilation to medial and lateral portions of knee, as seenin FIG. 3B.6.

A superior portion of impact material may feature name of company and/orproduct incised into material to identify brand and minimally affectsflexibility, material reduction, and ventilation, as shown in FIG. 3B.7,and utilizes features to correctly position the impact material onto thewearer's knee. For instance, a horseshoe knee saddle assists in thecorrect positioning of the impact material with respect to wearer'spatella, as shown in FIG. 3B.8. Medial [FIG. 3B.9], lateral [FIG.3B.10], and superior [FIG. 3B.11] folds enable proper seating of theimpact material and to control lateral translation of the impactmaterial and vertical translation of the impact material.

In some preferred implementations, the impact material utilizes featuresto assist in the proper positioning of the scales. The impact materialand scale interaction may be facilitated by a ridge and groove system,as shown in FIG. 4A.2, by mated locking shapes, as shown in FIG. 4A.3,and/or by a hook and loop system, as shown in FIG. 4A.4.

Fastener System

The fastener system incorporates a running strap and a receiving strap,which are both are attached to the fabric matrix at each strap'sproximal end. The running strap is formed and adapted to run through thereceiving strap, as shown in FIG. 5A.1 and FIG. 5B.1. In someimplementations, the running strap is narrower than the receiving strap.The running strap includes an attachment mechanism on a portion of aninside surface of a distal end and an outside surface of a proximal end,as shown in FIG. 5A.2 and FIG. 5B.2.

In other words, the receiving strap is formed and configured to receivethe running strap, and employs a slot to receive the running strap, asshown in FIG. 5A.3 and FIG. 5B.3. A length of the slot in the receivingstrap is oriented perpendicular to the length of the running strap andthe receiving strap. The slot is located toward the proximal end of thereceiving strap, which has an attachment mechanism on a portion of aninside surface of distal end and an outside surface of the proximal end,as shown in FIG. 5A.4, FIG. 5B.4.

The fastener system is secured by first running the running strapthrough the slot in the receiving strap and synching the knee pad bypulling on the straps, as shown in FIG. 5B.5. Equal tension applied tostraps running in opposing directions eliminates the effect ofshifting/rotating of the knee pad around the leg that other fasteningsystems have on other knee pads. The fastener system locks the runningstrap and the receiving strap in place through contact of the attachmentsurfaces located on both the inner and outer surfaces of the runningstrap and the receiving strap, as shown in FIG. 5B.6, and ensures asecure lock on the wearer's leg.

In some implementations, a position of the fastener system is locatedacross the superior tendons of the gastrocnemius muscle secures positionof knee pad and enhances ergonomics, as shown in FIG. 6A.1 and FIG.6B.1. The transverse cross sectional area of the wearer's leg located incoincidence with superior tendons of gastrocnemius muscle [FIG. 6C.1] isless than transverse cross sectional area of leg located in coincidencewith gastrocnemius muscle or tibiofemoral joint, as shown in FIG. 6C.2.

The fastener system seats best at the point of smallest circumference onthe wearer's leg, so that the knee pad remains secured in place due torequired increase in strap circumference in order to move onto largerpart of leg, as shown in FIG. 6D.1. A transverse cross sectional area ofleg located in coincidence with superior tendons of gastrocnemius musclechanges minimally during flexion and extension of the wearer's leg.Muscle tissue changes shape during flexion and extension, and results ina change in the transverse cross sectional area of the leg on planeintercepting muscle tissue, as can be seen in FIG. 6E.1. The wearer'stendon resists cross sectional area changes and therefore does notcontribute significantly to a change in transverse cross sectional areaof the leg, as shown in FIG. 6E.2. A reduction in apparent shear betweenthe fabric of the fastener system and the wearer's skin results indecreased awareness of the knee pad's attachment to the wearer's leg.

Knee Brace System

A fabric matrix employs a sleeve features located over the medial andlateral portions of the knee. The sleeve features are designed to acceptsupport ribs, to stabilize the knee pad and support the knee joint.Medial and lateral support ribs prevent superior portion of knee padfrom bunching downward. An inferior leg strap serves as an anchor due toplacement over the superior tendons of the wearer's calf muscles. Upperboundary fabric of the sleeve features rest on the support ribs andstabilize the superior portion of the knee pad in full extension mode.The support ribs emulate a motion control brace model. Medial andlateral support ribs support the medial and lateral ligaments of theknee joint, and the support ribs emulate an unload/offload brace model.Meanwhile, medial and lateral support ribs share torque load on thewearer's knee joint in bent-knee condition.

Although a few embodiments have been described in detail above, othermodifications are possible. Other embodiments may be within the scope ofthe following claims.

1. An apparatus comprising an attachment mechanism for attaching a basematerial to a body part of a wearer; a padding layer overlaying the basematerial; and a plurality of scales, each scale of the plurality ofscales being independently attached to the padding layer, each scaleeither at least partially overlapping or at least partially underlyingone or more adjacent scales to enable flexible adherence to a shape ofthe body part of the wearer.
 2. The apparatus in accordance with claim1, wherein the curvature of each scale cross-section parallel to thesagittal plane of the body matches a leg cross-section surface profile.3. The apparatus in accordance with claim 1, wherein each scale is adiamond shape.
 4. The apparatus in accordance with claim 3, wherein thediamond shape is asymmetrical.
 5. An apparatus comprising an attachmentmechanism for attaching a base material to a body part of a wearer; anda plurality of scales, each scale of the plurality of scales beingindependently attached to the attachment mechanism, each scale either atleast partially overlapping or at least partially underlying one or moreadjacent scales to enable flexible adherence to a shape of the body partof the wearer.
 6. An apparatus in accordance with claim 5, furthercomprising a padding layer overlaying the base material.
 7. Theapparatus in accordance with claim 5, wherein the curvature of eachscale cross-section parallel to the sagittal plane of the body matches aleg cross-section surface profile.
 8. The apparatus in accordance withclaim 5, wherein each scale is a diamond shape.
 9. The apparatus inaccordance with claim 8, wherein the diamond shape is asymmetrical. 10.The apparatus in accordance with claim 5, further comprising a paddinglayer overlaying the base material.